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KIRLOSKAR 2R1040 User Manual

KIRLOSKAR 2R1040
48 pages
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R1040 MAINTENANCE MANUAL
Page 1 of 48
Index
Sr.
No.
Topic Page
Nos
1 General 2
1.1 Service and Maintenance 2
1.2 Maintenance and Repairs 2
1.3 Safety 2
2 Engine details 2
2.1 Engine Name Plate 2
2.2 Engine illustrations 3
2.3 Engine lifting device 4
2.4
Lube oil system
5 – 8
2.5
Fuel supply system
9-10
2.6 Cooling System 11
2.7 Electrical System 12
3 Engine operation
3.1 Commissioning 13-16
3.2 Starting 16
3.3 Stopping 17
3.4 Operating conditions 18
3.5 Running-in period 19
4 Routine Maintenance 20
4.1 Maintenance Schedule 20
4.2 Top Overhaul and Major Overhaul Periods 21
5 Service and Maintenance 21
5.1 Maintenance of Lubrication system 21 - 27
5.2
Maintenance
of
Fuel
System
28
5.3
Maintenance
of
Cooling
System
29-30
5.4
Maintenance of Dry type air cleaner
31-34
5.5 Belt drives 35
5.6
Adjustments
36
5.7
Maintenance of Electrical Equipment
37
5.8
Checking of Fasteners
37
6
Troubleshooting and Remedial measures
38
6.1
Troubleshooting
38
6.2
Useful tips for Turbocharger
40
6.3
Periodical Inspection of Turbocharger for Generating set application
41
6.4
Recommendation for Turbocharger operation and maintenance
41
7
Instruction Manual for Electronic Governor
42
8
Engine preservation
43
8.1
Recommended Preservatives
43
8.2
Preservation Procedure
43
8.3
Commissioning
of
Preserved
Engine
44
9
Tightening Torque, Settings
45
9.1
Tightening Torque
45
9.2
Settings
46
10
Fuel timing
47

Table of Contents

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KIRLOSKAR 2R1040 Specifications

General IconGeneral
BrandKIRLOSKAR
Model2R1040
CategoryEngine
LanguageEnglish

Summary

General Engine Information

Service and Maintenance Guidelines

Guidelines for maintaining the engine's performance through sound practices and observing service intervals.

Maintenance and Repair Precautions

Safety precautions and procedures to follow when performing maintenance or repair work on the engine.

General Safety Instructions

General safety instructions and accident prevention regulations for engine operation and maintenance.

Engine Details and Identification

Engine Lifting Device

Instructions and precautions for safely lifting the bare engine or generating set using lifting hooks.

Lube Oil System

Lube Oil Circuit Description

Description of the engine's lube oil circuit, including lubrication methods and components like filters and coolers.

Lube Oil Specifications and Recommendations

Recommendations for lube oil specifications, including viscosity grades and standards compliance.

Fuel Supply System

Fuel Circuit Diagram

Schematic diagram of the fuel circuit, detailing the flow from the tank through filters to the fuel pump.

Fuel Specifications

Approved fuel specifications and important considerations for maintaining engine performance and fuel injection equipment.

Cooling System

Radiator Type Cooling System

Description and schematic diagram of the radiator-type cooling system used in the engine.

Coolant Recommendations

Recommendations for coolant mixture, including fresh water with additives and ethylene glycol for winter use.

Radiator Maintenance

Procedures for checking coolant level, cleaning radiator fins, and flushing the radiator.

Electrical System

Electrical Equipment Specifications

Details on the 12V electrical system, including alternator and starter specifications.

Battery Capacity Ratings

Battery capacity ratings and recommended battery capacities based on ambient temperature for optimal cold starting.

Engine Operation Procedures

Commissioning Steps

Steps and checks required before starting a new or overhauled engine for the first time.

Fuel System Bleeding

Procedure for bleeding the fuel system to remove air bubbles, ensuring proper fuel delivery.

Cooling System Filling

Procedure for filling the cooling water system with coolant and important safety precautions.

Valve Clearance Adjustment

Information on valve clearance adjustment, noting it's preset on new engines but requires checking after overhaul.

Routine Maintenance Schedule

Maintenance Schedule Overview

Comprehensive schedule detailing routine maintenance checks, cleaning, and renewal tasks at various running hour intervals.

Service and Maintenance

Lubrication System Maintenance

Procedures for maintaining the engine's lubrication system, including oil change intervals and level checking.

Changing Engine Oil Procedure

Detailed procedure for draining old engine oil and refilling with new oil, including safety precautions.

Lube Oil Filter Replacement

Instructions for replacing the spin-on lube oil filter cartridge, including preparation and installation steps.

Troubleshooting and System Maintenance

Centrifuge Cleaner Troubleshooting

A table listing common problems related to the centrifuge cleaner, their probable causes, and recommended actions.

Fuel Filter Replacement

Instructions for changing fuel filter cartridges (pre-filter and micro-filter) according to the maintenance schedule.

Cooling System Maintenance Overview

Overview of the engine cooling system components and chemical treatment recommendations for coolant.

Air Cleaner Maintenance

Dry Type Air Cleaner Description

Description and maintenance procedures for the dry type air cleaner, including cleaning and replacement of elements.

Air Cleaner General Maintenance

General maintenance guidelines for the air cleaner, including daily checks and important warnings.

Air Cleaner Element Cleaning

Detailed steps for cleaning the air filter element when the restriction indicator shows a red signal.

Air Cleaner IMPORTANT Warnings

Crucial warnings about using excessive air pressure and checking elements for damage before installation.

Belt Drive Maintenance

Engine Adjustments

Valve Clearance Checking and Adjustment

Detailed procedure for checking and adjusting the valve clearance using feeler gauges and a screwdriver.

Electrical Equipment Maintenance

Fastener Checking

Troubleshooting Engine Problems

General Troubleshooting Guide

A diagnostic chart listing common engine starting and running problems, their causes, and recommended solutions.

Turbocharger Operation and Maintenance

Electronic Governor System

Tightening Torque and Settings

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